Download 517760 DX1 SmartLoad Service Manual

DRYER
Models DEGX1 & DGGX1
517760
MANUAL 517760 - DATE OF ISSUE
JULY 2004
The specifications and servicing procedures outlined in this manual are subject to change without
notice.
The latest version is indicated by the reprint date and replaces any earlier editions.
Fisher & Paykel Appliances Ltd
Technical Publications
PO Box 58-732, Greenmount, Auckland
78 Springs Road, East Tamaki
New Zealand
Telephone: 09 273 0600
Facsimile: 09 273 0656
Fisher & Paykel Appliances Inc
27 Hubble, Irvine
California, CA92618
USA
Telephone: 949 790 8900
Facsimile: 949 790 8911
COPYRIGHT  FISHER & PAYKEL APPLIANCES LTD 2004
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CONTENTS
1 Servicing Requirements .................................................................................................................. 7
1.1
Health & Safety....................................................................................................................................7
1.1.1 Electrical Safety ...........................................................................................................................7
1.1.2 Electrostatic Discharge................................................................................................................7
1.1.3 Good Working Practices..............................................................................................................7
1.1.4 Safety Test...................................................................................................................................7
1.1.5 Sheet Metal Edges ......................................................................................................................7
1.1.6 Gas Leakage Test .......................................................................................................................7
1.2 Specialized Tools ................................................................................................................................7
1.2.1 Fisher & Paykel Smart Tool.........................................................................................................7
2 Model Information .......................................................................................................................... 8
2.1
2.2
Model Number.....................................................................................................................................8
Serial Number .....................................................................................................................................8
3 Technical Overview ........................................................................................................................ 9
3.1
3.2
3.3
3.4
3.5
Finish ...................................................................................................................................................9
Electrical Supply..................................................................................................................................9
Dimensions..........................................................................................................................................9
Maximum Capacity (Full Load) ...........................................................................................................9
Principles of Operation ......................................................................................................................10
3.5.1 Electronic Control ......................................................................................................................10
3.5.2 Loading ......................................................................................................................................10
3.5.3 Lid Lock Control.........................................................................................................................10
3.5.4 Lint Filter ....................................................................................................................................11
3.5.5 Airflow ........................................................................................................................................12
3.5.6 Temperature Control .................................................................................................................13
3.5.7 Cool Down .................................................................................................................................13
3.5.8 Drum Parts.................................................................................................................................13
3.5.9 Drum Control. ............................................................................................................................15
3.5.10 Drum Door Control ....................................................................................................................15
3.5.11 Heater Control. ..........................................................................................................................18
3.5.12 Auto Sensing .............................................................................................................................19
3.5.13 Regulator Valve .........................................................................................................................20
3.5.14 Gas Flame Detector ..................................................................................................................21
3.6 Gas Igniter .........................................................................................................................................22
3.7 Gas Regulator Valve .........................................................................................................................22
3.8 Gas Flame Detector ..........................................................................................................................22
3.9 Thermostat Cutout – Automatic Reset (Gas)....................................................................................22
3.10 Thermostat Cutout – Manual Reset (Gas) ........................................................................................23
3.11 Element Assembly 240V 3.6 KW ......................................................................................................23
3.12 Element Assembly 240V 1.4KW .......................................................................................................23
3.13 Thermostat Cutout – Automatic Reset (Electrical)............................................................................23
3.14 Thermostat Cutout – Manual Reset (Electrical) ................................................................................24
3.15 Motor – 3 Phase 240W......................................................................................................................24
3.16 Exhaust Temperature Sensor Loom .................................................................................................24
3.17 Lid Lock .............................................................................................................................................24
3.18 Motor Control Module........................................................................................................................25
3.19 Sensor Module ..................................................................................................................................25
3.20 Display Module..................................................................................................................................25
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4 Diagnostics ....................................................................................................................................26
4.1
4.2
4.3
Overview ...........................................................................................................................................26
Fault Code Summary ........................................................................................................................27
Diagnostic Mode ...............................................................................................................................34
4.3.1 Entering the Diagnostic Mode ...................................................................................................34
4.3.2 Entering the Data Download Mode ...........................................................................................34
4.3.3 Entering the Showroom Mode...................................................................................................34
5 Fault Diagnostics ...........................................................................................................................35
5.1
Problem - No Power..........................................................................................................................35
5.1.1 Check the Continuity of the Power Cord (Electric)....................................................................35
5.1.2 Check the Continuity of the Main Harness (Electric) ................................................................35
5.1.3 Check the Continuity of the Power Cord (Gas).........................................................................36
5.1.4 Check the Continuity of the Main Harness (Gas)......................................................................36
5.2 Problem - No Heat ............................................................................................................................36
5.2.1 Check All Thermostats (Gas and Electric) ................................................................................36
5.2.2 Check the Elements (Electric Only) ..........................................................................................36
5.2.3 Check Voltage Across Elements (Electric Only) .......................................................................37
5.2.4 Measure the Current Draw for Each Element (Electric Only) ...................................................37
5.2.5 Check the Gas Valve/Regulator (Gas Only) .............................................................................37
5.2.6 Check the Flame Detector (Gas Only) ......................................................................................38
5.2.7 Check the Igniter (Gas Only).....................................................................................................38
5.2.8 Check the Exhaust Sensor (Gas and Electric)..........................................................................38
5.2.9 Check Inlet and Outlet Duct Seals ............................................................................................38
5.3 Problem – Drum Does Not Rotate ....................................................................................................38
5.3.1 Check for Fault Code. ...............................................................................................................38
5.3.2 Check the Integrity of the Belt. ..................................................................................................38
5.3.3 Check the Motor Windings. .......................................................................................................39
5.4 Problem - Under Drying/Damp..........................................................................................................39
5.4.1 Possible User Faults .................................................................................................................39
5.4.2 Possible Installation Faults........................................................................................................39
5.4.3 Possible Maintenance Problems...............................................................................................39
5.4.4 Check the Inlet and Outlet Duct Seals ......................................................................................39
5.4.5 Check the Heating Circuits........................................................................................................39
5.4.6 Check the Moisture Sensing Circuit ..........................................................................................39
5.5 Problem - Over Drying ......................................................................................................................40
5.5.1 Check the Moisture Sensing Circuit ..........................................................................................40
6 Service Procedures ........................................................................................................................41
6.1
6.2
6.3
6.4
Removal of Lid ..................................................................................................................................41
Components in Console Area ...........................................................................................................41
Removal of Display Module ..............................................................................................................41
Removal of Top Deck .......................................................................................................................42
6.4.1 If the top deck is to be removed for replacement:.....................................................................42
6.4.2 If the top deck is to be removed to gain access to other components:.....................................42
6.5 Removal of Lid Lock..........................................................................................................................43
6.6 Components Within Cabinet .............................................................................................................43
6.7 Removal of Front Cabinet Brackets ..................................................................................................43
6.8 Removal of Door Grabber Assembly ................................................................................................44
6.9 Removal of Door Grabber Actuator ..................................................................................................44
9.10 Removal of Door Grabber.................................................................................................................45
6.11 Removal of Door Bracket..................................................................................................................46
6.12 Removal of Drum Door .....................................................................................................................46
6.13 Removal of Drum Door Buffers.........................................................................................................47
6.14 Removal of Drum Door Key Bracket.................................................................................................47
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6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
6.31
6.32
6.33
6.34
6.35
6.36
6.37
6.38
6.39
6.40
6.41
6.42
6.43
Removal of Drum Door Scraper........................................................................................................47
Removal of Drum and Chassis Assembly.........................................................................................48
Removal of Outlet Panel Assembly...................................................................................................48
Removal of Outlet Duct Assembly ....................................................................................................49
Removal of Outlet Duct Bearings......................................................................................................49
Removal of Outlet Duct Seal .............................................................................................................49
Removal of Exhaust Sensor..............................................................................................................50
Removal of Lint Collector Housing....................................................................................................50
Removal of Conductivity Contacts ....................................................................................................50
Removal of Belt Tensioner ................................................................................................................51
Removal of Inlet Panel Assembly .....................................................................................................52
Removal of Inlet Duct Seal................................................................................................................52
Removal of Inlet Bearing Shaft..........................................................................................................53
Removal of Drum Inlet Bearing .........................................................................................................53
Removal of Belt .................................................................................................................................54
Removal of Drum ..............................................................................................................................54
Removal of Lint Filter Assembly........................................................................................................54
Removal of Motor ..............................................................................................................................54
Removal of Fan .................................................................................................................................55
Removal of Fan Motor Housing ........................................................................................................55
Removal of Motor Control Module ....................................................................................................56
Removal of Sensor Module ...............................................................................................................56
Removal of Gas Igniter (Gas Models)...............................................................................................56
Removal of Flame Detector (Gas Models)........................................................................................56
Removal of Thermostats ...................................................................................................................57
Removal of Gas Regulator Valve, Pipe and Burner Tube (Gas Models) .........................................57
Removal of Elements (Electric Models) ............................................................................................57
Removal of Front Foot Bracket Assembly.........................................................................................58
Removal of Rear Foot Bracket Assembly .........................................................................................58
7 Wiring Diagrams........................................................................................................................... 60
7.1
7.2
U.S.A. Model (Electric) ......................................................................................................................60
U.S.A. Model (Gas) ...........................................................................................................................61
8 Fault Finding Flow Charts ............................................................................................................ 62
8.1
8.2
8.3
8.4
8.5
8.6
8.7
No Power...........................................................................................................................................62
No Heat (Electric Models) .................................................................................................................63
No Heat (Gas Models).......................................................................................................................64
Drum Door Not Opening/Closing ......................................................................................................65
Drum Does Not Rotate ......................................................................................................................66
Clothes Take Too Long to Dry ..........................................................................................................67
Noisy..................................................................................................................................................68
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1
Servicing Requirements
1.1
Health & Safety
Note: When servicing the SmartLoad™ electronic dryer, health and safety issues must be
considered at all times. Specific safety issues are listed below to remind service people of
the health and safety issues.
1.1.1
Electrical Safety
WARNING! TO AVOID ELECTRIC SHOCK!
Do not attempt to service this dryer without suitable training and qualifications.
Ensure the mains power has been disconnected before servicing any part of the dryer. If
the power is required to be on for electrical fault finding, or observing gas flame or
checking operation, then extreme care should be taken not to make contact with electrical
components other than with testing probes. Ensure the dryer is turned off when removing
any electrical component or connection.
1.1.2
Electrostatic Discharge
Electronic components are prone to damage from electrostatic discharges. The electronic
modules in this product contain no user serviceable components and breaking seals to
access internal components of an electronic module may void the product warranty. Avoid
contact with PCB edge connectors when handling electronic modules.
1.1.3
Good Working Practices
Ensure the work areas are kept tidy and free of hazards while servicing the dryer. On
completion of the servicing, ensure the dryer and work areas are left clean and tidy.
1.1.4
Safety Test
On completion of any service carried out to the dryer, all safety tests as required by law
must be carried out.
1.1.5
Sheet Metal Edges
When working around cut sheet metal edges use appropriate gloves or protection to
eliminate the chance of receiving a laceration.
1.1.6
Gas Leakage Test
On completion of any service carried out on a gas dryer, all safety tests as required by law
must be carried out.
1.2
Specialized Tools
1.2.1
Fisher & Paykel Smart Tool
Fisher & Paykel have developed diagnostics software for use in a laptop computer or a
handheld palm computer. With this software, diagnostic data may be downloaded from
the appliance to assist in servicing.
Authorised service centres may download this software from the Fisher & Paykel web site.
- 7 -
2
Model Information
The product serial plate is located on the upper rear of the cabinet and contains the
following information:
2.1
Model Number
The model number contains the following information:
D E G X 1
Series
Size
Feature Level
Heating Type (E = Electric, G = Gas)
Product Type (Dryer)
2.2
Serial Number
The serial number consists of three letters and six digits and contains the following
information:
Example:
B E N
123456
Sequential Serial Number
Manufacturing Plant Code
FISHERPAYKUL Code indicates month of
manufacture
CUMBERLAND Code indicates year of
manufacture
Cumberland Code
Letter
C
U
M
Year
1
2
3
B
4
E
5
R
6
L
7
A
8
N
9
D
0
Fisherpaykul Code
Letter
F
I
S
Month
1
2
3
H
4
E
5
R
6
P
7
A
8
Y
9
K
10
U
11
L
12
Manufacturing Plant Code
A
Laundry – Australia
F
Refrigeration – New Zealand
M
Range & Dishwasher
N
Laundry – New Zealand
Q
Refrigeration - Australia
In the example above, the appliance was manufactured in the fifth month of the fourth year
(2004) at the New Zealand Laundry plant.
- 8 -
3
Technical Overview
3.1
Finish
Cabinet:
Touch-Up Paint:
Lid:
Console:
Drum:
Top Deck:
3.2
Electrical Supply
USA Electric
USA Gas
3.3
Pre-paint (Polyester)
White #503086
ABS Co-injected, one piece
ABS with Polycarbonate insert for control panel
Stainless steel grade 430T
Polypropylene
Operating Voltage Maximum Current
220/240V AC 60Hz
24 amps
110/120V AC 60Hz
6 amps
Dimensions
Height to lid
Open
Closed
Height to console
Width
Depth
55½ in - 56¾ in
37½ in - 38½ in
40¼ in - 41½ in
27 in
27½ in
1410mm – 1440 mm
950 mm – 980 mm
1020 mm – 1050 mm
685 mm
700 mm
Note: Exact height of the SmartLoad™ dryer is dependent on how far the feet are inserted
into the base of the dryer.
Weight Packed
Unpacked
3.4
152 lbs (69kg)
134 lbs (61kg)
Maximum Capacity (Full Load)
Drum Volume
6.5 cubic feet (.184 cubic metres)
- 9 -
3.5
Principles of Operation
1.1.1
Electronic Control
The 120V or 220/240V power supply is connected to
the motor control module which rectifies to DC for
use by its own controller and peripherals, and also
for the sensor module. The motor control module
has an optically isolated serial communications port
to the sensor module from which it receives
commands for operating the drum motor and the
heater(s). The motor control module does the actual
control of those devices.
The sensor module is responsible for the overall
control of the dryer, including the input and output of
all other peripherals. The sensor module controls
the lid lock and the drum door actuator, senses the
drum position and speed, measures. the exhaust
duct temperature through the exhaust sensor and
measures the dampness of the clothes load via the
sensor bars.
Sensor Module
Display Module
Motor Control Module
The algorithm for when the heaters are turned on and off, and also for the speed and
direction of the motor, is implemented within the sensor module, but the switching of the
elements or gas heater, and control of the motor, is done by the motor control module in
response to the commands from the sensor module.
When the mains power is first applied to or restored to the sensor module, the dryer will
endeavour to continue operating from when the power was lost. If mains power was lost
during a drying cycle, it will continue to dry to the same set dryness level, otherwise the
machine will return to have the drum door open and the lid unlocked.
The display module is a “Dumb” module and user interface that passes user settings to the
sensor module and displays information in the form of LED displays transmitted from the
sensor module.
3.5.2
Loading
The dryer always stops with the drum door open. The user places the drying load into the
drum, closes the lid, pushes the Power button, selects the required cycle and presses the
Start/Pause button. The lid will lock, the drum will rotate and the door grabber will slide
the drum door closed. The door grabber will then move clear of the drum.
3.5.3
Lid Lock Control
™
SmartLoad has a lock installed in the lid to provide added safety while the dryer is
operating. It ensures that the lid cannot be opened while the drum is rotating.
The lid lock is a mechanism driven by a DC solenoid and prevents the lid being opened
when the drum is rotating. If the lid lock mechanism is not engaged for any reason,
including open circuit or short circuit, a “Locked” is not assumed. If unable to lock after the
user has requested a start, a User Warning will be given.
- 10 -
The LID LOCKED LED (above the Start/Pause button) comes on when the lid is
locked to tell the user when they cannot open the lid.
• When the LID LOCKED LED is illuminated, the lid is locked and the lid cannot be
opened.
• When the LID LOCKED LED is not illuminated, the lid is not locked and the lid
can be opened.
• If the LID LOCKED LED is flashing, the lidlock is in the process of locking or
unlocking, (i.e. while the dryer coasts down or Start/Pause has been pressed).
During this stage the lid cannot be opened.
The lid must be closed before the drying cycle can start. If Start/Pause is pressed with
the lid open, the dryer will beep, signalling the lid needs to be closed. Once the lid has
been closed and Start/Pause is pressed, the lidlock will be activated and the cycle
begins.
If the power fails, either from a power cut or having been switched off at the wall, the lid
may be opened. In some circumstances the drum door may not be in the open
position. When the power is restored the dryer will automatically recommence the
drying cycle as long as the lid is shut.
If it is absolutely necessary to remove the load before the power is
restored, follow the steps below:
1. Ensure the dryer is disconnected from the power supply.
2. Open the lid (this will already be unlocked).
3. On the left hand side of the dryer there is a thumb tab that
appears when the drum is not open. Press the thumb tab and
rotate the drum by hand towards the back of the machine.
4. Hold the thumb tab down until the drum door starts opening.
5. Keep rotating the drum until the door is fully open and the drum
comes to a stop.
6. The clothes can now be removed.
7. Close the lid once the clothes have been removed.
8. Re-connect the power supply to the dryer.
The drum door will automatically close and the dryer will resume
normal operation when power is restored.
3.5.4
Lint Filter
Lint laden air passes through the small
holes in the outlet end of the drum (the
small holes around the lint bucket). The
lint removal system is directly behind
these holes. As this air moves through
the holes it is forced through the lint
filter. The fan then
sucks the air down
through the duct
and out the back
of the dryer.
Lint Filter
Lint Filter
- 11 -
The lint filter in the SmartLoad™ dryer is circular and is positioned next to the drum. When
the drum rotates the lint filter rotates with it. The filter is made of very fine 200-micron
mesh. All clothes dryers produce potentially flammable lint. Use of a fine mesh enables a
lint filter to catch more lint from the air before it reaches the exhaust ducting. That reduces
the possibility of any blockages or hazards caused by the accumulation of lint.
There is a scraper situated on the top of the lint collecting housing which the filter moves
past. Where the lint on the filter builds up, the lint begins to touch the scraper, and is
automatically scraped off. Because the scraper is directly above the lint bucket it falls
straight in.
The scraper helps achieve consistent airflow throughout
the drying cycle by continuously removing any
accumulated lint from the mesh of the filter.
Scraper
The dryer user manual and lid label instruct the user to
empty the lint bucket before the lint reaches the top of the
transparent part of the bucket. If the lint bucket overflows
due to the user not emptying it, the SmartLoad™ dryer
can clear itself. The user just needs to empty the bucket
and run the dryer on a cycle for approximately 20 minutes.
The dryer will free all the trapped lint and will re-deposit it
back into the lint bucket.
Lint
Lint
3.5.5
Airflow
An intake grill at the bottom rear of the cabinet provides an entry point for the airflow
through the dryer via four large louvred slots. Additional air is drawn in at the front of the
cabinet under the front panel. A fan on the exhaust side of the drum draws the air over the
heating elements/gas burner located in a combustion chamber, through an inlet duct and
into the drum.
The air exits the drum through a self-cleaning lint filter in the drum outlet duct, then passes
through the fan housing and out the rear exhaust vent situated at the bottom rear of the
cabinet.
Air Intake Grill
Rear Exhaust Vent
Lower Rear Cabinet Panel
- 12 -
Belt
Lint Removal
System
Hot Air
Drum
Belt Tensioner
System
Fan
Outlet
Motor
Cold
Air
Heater
3.5.6
Temperature Control
The user can select either a dryness level that they require or a timed drying period. Auto
sensing of the clothes load dryness level is achieved by touch sensors that sense the
moisture content of the load. An exhaust temperature sensor is used to monitor the
exhaust temperature. The controller limits the temperature to what is required for the
various cycles.
An auto reset thermostat located on the burner housing also limits the heat into the dryer,
but if it fails to operate, them a manually resetable thermostat also situated on the burner
housing will trip at 318oF (150oC), turning off the heat to protect the clothes.
3.5.7
Cool Down
The dryer enters a cool down period at the end of the cycle. During this period the dryer
continues to run with the heating elements/burner turned off, blowing cool air through the
load to help prevent creasing. If an Auto Sensing cycle has been selected, the cool down
period will continue until the exhaust temperature drops to 95oF (35oC). If a Timed Dry
cycle has been selected, the cool down period will run for the last 5 to10 minutes of the
timed dry period.
3.5.8
Drum Parts.
1. Drum Inlet End: Allows inlet air to pass through. This is how air enters the drum. It
also houses the inlet central bearing assembly, about which the drum rotates.
2. Drum End Outlet: Provides the route for air to exit the drum as well as securing
the lint filter. The outer face has dimples which are collectively referred to as “the
drum tachometer”. The central flange of the drum end outlet is supported and
guided by seven bearing pads which are mounted in the outlet duct.
3. Vanes: Encourage clothes to tumble during the drying cycle.
- 13 -
4. Drum Door: Slides back along grooves in the bridge to provide access into the
drum.
4
2
1
3
5. Door Bracket: Secures and seals the drum in the closed position and houses
components for latching the door.
6. Hinge Arm: Part of the door assembly, which is contacted by the door grabber for
opening and closing the door. It also latches the door closed over the end of the
track.
7. Locking Bar: Attached to its ends are the hinge arms. Its function is to hold these
hinges in the correct orientation.
8. Hinge Spring: Springs the hinge arm down to ensure latching when the door is
closed.
5
8
7
6
There is also a Drum Door Scraper that prevents clothes from being drawn into the gap
between the drum and the door when the door is opening, and a Key Bracket that
prevents the door from closing when the clothes are protruding.
- 14 -
3.5.9
Drum Control.
The drum is coupled to a three phase induction motor
by way of a pulley on the motor shaft, which drives
via a “V” belt and belt tensioner system. The motor
control module controls the motor by generating the
three phases from a high voltage rectified DC rail.
When tumble drying, the drum is tumbled at 47 RPM,
during opening and closing at 5 RPM, and at other
speeds as required and requested from the sensor
module.
Feedback on speed is via the drum
tachometer signal, which comes via the sensor
module.
When drying, the drum rotates in the door closing
direction for 4 minutes, after which it coasts to stop
Tensioner
and reverses for 40 seconds, then coasts to stop BeltSystem
before repeating the reversing throughout the drying
and cooling cycle.
The reversing of the drum
direction reduces tangling.
Belt
Three Phase
Motor
During Wrinkle Guard the drum rotates in one direction for 30 seconds, then stops for 5
minutes without opening the drum door, after which it goes in the opposite direction for 30
seconds, then pauses again before turning off. If the user does not remove the clothes
load, the cycle is repeated 255 times, which take approximately 23 hours.
The drum tachometer uses pressed “dimples”, formed directly into the drum end outlet,
spaced every 2 degrees to provide positioning information while also providing speed data.
There is a 15 degree “gap” to provide the reference for absolute position. An infrared
diode and optical receiving transistor provide the reading of the “dimples.” The digital
signal is output to the motor control module, which uses the signal for speed controlling the
drum. The drum position is monitored by the sensor module, which uses the position for
both speed commands and drum door actuator control.
3.5.10
Drum Door Control
The drum door is opened and closed by the door
grabber, which is positioned by an actuator driven
by a small DC brush motor.
A mechanical interlock prohibits the drum door from
latching closed if garments get caught in the door
opening. With the door unable to close, the drum
will stall, which will be sensed by the motor control
module and corrective action will occur.
Reference
Point
Dimples
After Start/Pause is pressed when the dryer is
waiting with the drum door open:
1. The lid will lock.
2. The sensor module assumes the drum door is open at “Home” and rotates the drum at
5 RPM in the drum door close direction. If it is “Home” and the grabber lowered, the
door will close at 78 degrees away from “Home”. Note: If the door is closed and the
grabber lowered, the drum will simply rotate with a slight rubbing noise of the grabber
on the drum.
- 15 -
3. If the motor stalls after the drum has moved at least 42 degrees, a “Clothes Jammed”
fault will be internally flagged and the drum will reverse and the door will open before
trying to close again. After three unsuccessful attempts, the drum door will open, the
lid will be unlocked and the relevant User Warning will occur.
4. At the “Retract Grabber Position”, 142 degrees from “Home”, the sensor module
begins moving away the grabber.
• If a fault is detected during the actuator movement, the operation of the actuator will
be checked. The drum will stop and an attempt will be made at moving the actuator
back to lower the door grabber.
• If a fault is again detected, a maximum of five attempts are made at moving the
grabber, alternating the direction with each attempt, until finally the dryer will display
the relevant fault code and remain in the stationary position with the lid unlocked. If
however the actuator is operated correctly, the grabber is left in the retracted
position.
5. When the grabber is confirmed to have retracted, the drum motor is sped up to 47
RPM and the sensor module will begin or continue the normal drying operation.
When Pause is pressed or the drying is completed:
1. If the drum is rotating in the Close direction, then it will be reversed and the drum
speed will be set at 20 RPM, at which speed the position of the drum is verified using
the tacho “Gap” as its reference. If however the drum was moving in the open
direction, its position may have already being verified at the higher speed, but if not,
will be set to slow down to 20 RPM until the position is verified. If within 40 seconds
the sensor module is unable to verify its position, either because no “Gap” of sufficient
arc has been detected or a correct count for a complete revolution of the drum cannot
be obtained, then a fault code will be displayed.
2. Once the position is known, the drum speed begins to slow to 5 RPM. Provided the
drum speed has reduced to at least 18 RPM when the drum position is 132 degrees
from the extended door grabber position (210 degrees from “Home”), the lowering of
the grabber begins.
Door Grabber is lowered against the Wrapper
3. As the bridges approach the lowered door grabber, wings on each side of the grabber
enter the bridge channels. If the wings do not enter the channels, the grabber will be
unable to open the drum door (refer to the diagram below).
As the drum continues to rotate, the engagement ribs attached to the door grabber
unlatch the drum door hinge arms, lifting them out of the channel slots. The hinge
arms are raised by details on the door grabber to the top face of the bridge channels.
The drum continues to rotate in the opening direction, while the drum door is held
stationary by the door grabber.
- 16 -
Bridge Channels
Hinge Arm and Locking Bar are unlatched by
the Door Grabber
Engagement Ribs contacting Hinge Arm
As the drum reaches the fully opened position, details on the drum bridges hit the door
grabber, causing the motor to stall and the drum to stop. The drum is now in a fully
opened position, where the user can load or unload garments from the dryer.
Drum is stopped by the Door Grabber
Door Partially Opened
The dryer electronics can determine whether the drum has reached the correct
position by way of the optical sensor attached to the Sensor board, which uses the
dimples on the drum end outlet to determine the drum position.
4. Provided there is no failure in extending the grabber, the drum door will be opened.
However, if a failure is detected in the actuator’s movement, the drum will immediately
stop. The dryer will then attempt to retract the grabber. If the grabber is successfully
retracted, the sequence will repeat from step 1 of this opening sequence. However, if
the actuator fails to successfully move the grabber after repeated attempts, the sensor
module will stop the drum in its closed state and a fault code will be displayed. Five
attempts are made to open the drum door before flagging the fault.
5. The lid lock will be released.
When the power is first switched on or restored after interruption:
In normal circumstances where the previous cycle was completed successfully, when
power is reapplied to the product, the sensor module will assume the door is open and the
machine is at rest. In all other cases it will either continue operating or return to the
“home” position so that the drum door is open and the lid is unlocked. If for some reason
the drum door is not open, then the operator will need to first start, then pause the
machine to return it to its drum open position. When the dryer recommences operation,
the sensor module must allow for the situation where the drum door may be part way
through an opening or closing sequence. In order to do this without the risk of damaging
any of the mechanical parts, the sensor module executes the following sequence:
- 17 -
1. Moves the drum in the open direction to check if the user has manually opened the
drum door, and if found so, will stop and assume the normal off position.
2. If not “Home”, moves the drum so as to close the door, moving as far as would
normally be required to close the door from the “Home” (fully open) position.
3. The sensor module then operates the grabber and leaves it in the retracted position.
4. Provided the grabber was successfully retracted, the drum will continue rotating in the
Close direction; ramp up to full speed, and the dryer will continue its cycle.
3.5.11
Heater Control.
The heaters are controlled in response to the selected drying cycle chosen and also
according to other technical requirements such as reversing and over heating.
In the electric heater models, the heater housing is fitted with two elements that supply
about 5 kW of heat when both are on. There is a 3.6kW and a 1.4kW element that are
used at various times depending on the cycle chosen and the drum/fan direction. For the
gas model, a gas burner is used to provide the heat, and this is turned on for lower duty
times for the Permanent Press and Delicate cycles to apply similar heating as the electric
model.
When drying, the heater is only switched on when the drum is up to speed. Because of
the time it takes for the element to cool down after switching off, the larger element in the
electric model is switched off a few seconds before stopping to reverse, to prevent
excessive heat entering the drum.
The software in the motor control module responds to the switching on and off of the
heater as requested by the sensor module. It also monitors the automatic thermostat on
the heater housing for excessive restriction of airflow, and if detected, will set a User
Warning but continue the drying cycle until the end of the cycle when the warning will
reset. If the User Warning occurs, the drying will take a longer time to complete and the
load will possibly end up a little damp.
Each cycle, Denim through to Delicate, has a temperature limit, as defined in the table
below, as measured in the exhaust air. After switching off at the limit, the temperature has
a hysteresis of 5 degrees below these temperatures when the heat source switches back
on.
Denim
Regular
149oF (65oC)
149oF (65oC)
Permanent
Press
140oF (60oC)
Delicate
127oF (53oC)
When tumbling the heat source is turned on as shown in the table below:
Electric
Door Close Direction
Door Open Direction
4 minutes
40 seconds
Element 2/3
Element 1/3 Heat
Element 2/3
Element 1/3
Heat
Heat
Heat
Denim
ON
ON
OFF
ON
Regular
ON
ON
OFF
ON
P.Press
ON
OFF
OFF
ON
Delicate
ON
OFF
OFF
ON
Air Dry
OFF
OFF
OFF
OFF
- 18 -
Gas
Door Close Direction
Door Open Direction
4 minutes
40 seconds
Gas Ignition
Gas Heating
delay
Denim
30 seconds
3 minutes 30 seconds
No Heat
Regular
30 seconds
2 minutes 30 seconds
P.Press
30 seconds
2 minutes 30 seconds
Delicate
30 seconds
2 minutes 30 seconds
Air Dry
No Heat
No Heat
Note: During heating, if the temperature exceeds the limits for the particular cycle, the
heat is turned off and can significantly reduce the heating time. This is particularly true for
gas dryers which require the 30 second ignition time.
Cycle times can be affected by a number of factors including:
• The cycle chosen
• Load size
• Size of items
• Type of fabric
• Load wetness
• Venting method
• Location of dryer
• Condition of exhaust ducts
• Heat used (electric, natural gas or LPG gas)
• Environmental conditions (temperature, humidity)
The table below shows approximate cycle times (in minutes) for an 8 pound (3.6 kg) load
dried using the regular cycle.
Smartload™ Electric
Smartload™ Gas
Damp
26
29
Damp/Dry
36
38
Dry
47
47
Dry/Extra Dry
50
49
Extra Dry
50
51
3.5.12
Auto Sensing
When wet or damp clothes are loaded into a dryer they are partially saturated with water
which is a relatively good conductor of electricity. In the SmartLoad™ dryer, sensor bars
are used to measure the conductivity. When moisture in the clothes touches across the
sensor bars (located beneath the lint bucket) their conduction is measured. As the clothes
dry they become less conductive and it is this measurement that is used to calculate the
dryness of the clothes load.
Large loads will brush against these moisture sensor bars more frequently than small
loads, and this strike count is used to help determine the dryness of different sized loads.
Different fabrics retain moisture differently; a thick towel containing a lot of moisture will
often conduct the same as a light synthetic garment containing very little. It is this
difference in fabric characteristics plus the initial unknown moisture content that makes the
calculation of dryness reasonably complex.
- 19 -
3.5.13
Regulator Valve
In a gas dryer, the regulator valve forms part of the gas control system and performs the
function of regulating the gas pressure into the burner venturi and turning the gas flow on
and off.
The regulator valve consists of two solenoid shut-off valves, a gas pressure regulator and
a gas orifice assembled into a single cast body. The pressure regulator is factory set to
maintain 3½ inches of water column (WC) gas pressure at the orifice (0.87kPa). The
regulator is service adjustable. The two solenoid valves are in series such that the gas
flowing through the pressure regulator must pass through both valves to get to the orifice
and burner. At dryer start up, the gas igniter is energised and the first valve is opened.
Once the gas igniter has reached ignition temperature, the gas flame detector operates the
second valve, allowing gas to flow through the orifice and into the burner venturi, and
ignition takes place. The second valve is held open only when a flame or hot ignition is
detected by the gas flame detector.
The orifice is a precisely drilled brass plug screwed into the outlet port of the regulator
valve. The orifice extends into the burner venturi. The combination of regulated pressure
and orifice size provides the proper volume of gas for the heat rating of the burner. The
regulator valve comes from the factory sized and adjusted to deliver heat at the rate of
20,000 BTUs per hour, using natural gas.
Information fed back
to gas flow regulator
and valves from
Flame Detector
Gas Pipe
Gas Flow
Regulator
and Valves
Orifice
Igniter
Combustion
Chamber
Gas Pipe
Gas Flow
Regulator and
Valves
Orifice
Burner
Venturi
Igniter
Igniter
Bracket
Gas Burner Assembly
While natural gas is most commonly used, the regulator valve is also able to
accommodate the use of LPG. In this case, a LPG conversion kit (part number 395489) is
used to modify the regulator valve to achieve the correct volume of gas flow for LPG.
- 20 -
3.5.14
Gas Flame Detector
The gas flame detector is an essential safety device that forms part of the control system
for the gas burner. It consists of a thermostatically operated single-pole, single-throw,
normally closed bimetallic switch that is sensitive to radiant energy.
The function of the gas flame detector is to detect when the gas igniter has reached an
appropriate temperature to ignite the incoming gas/air mixture, and then energise the
secondary valve in the regulator assembly, releasing the gas into the burner venturi. The
gas flame detector also detects the radiant heat from the flame once ignition is achieved
and keeps the secondary valve open as long as it detects a flame present. If for any
reason the flame is extinguished, the flame detector contacts will close in approximately 30
to 50 seconds, causing the secondary valve to close, thereby turning off the gas supply to
the burner venturi.
The system takes approximately 20 to 30 seconds to operate the regulator valve once the
gas ignitor has been energised. This length of time is a function of the thermal inertia of
both the gas ignitor and the gas flame detector.
The gas flame detector is attached to the side of the combustion housing with a tabthrough-slot and one screw. A rectangular hole in the combustion housing adjacent to the
“window” in the gas flame detector allows the radiant energy to reach the gas flame
detector.
- 21 -
3.6
Gas Igniter
Part Number
Cold Resistance
Typical Temperature
Minimum Temperature
Maximum Temperature
3.7
395188
40 - 200 Ohms
2399°F (1315°C) @ 120V
1805°F (985°C) @ 80V
3092°F (1700°C) @ 132V
Gas Regulator Valve
Combination gas pressure regulator and dual automatic
gas valve.
Part Number
395369
Voltage Rated
120 Volts AC 60 Hz
Resistance Across Terminals
1&2
1.4 kOhms
1&3
560 Ohms
3&4
1.3 kOhms
Orifice
#43
Regulated pressure
3.5” H2O
3.8
Gas Flame Detector
Part Number
395194
Voltage Rated
120 Volts AC 60 Hz
Contacts normally closed, open with heat.
3.9
Thermostat Cutout – Automatic Reset (Gas)
Part Number
Type
Trip Temperature
Reset Temperature
395192
SPST
230oF ± 5o (110°C ± 3o)
203oF ± 8o (95°C ± 4.5o)
- 22 -
3.10
Thermostat Cutout – Manual Reset (Gas)
Part Number
Type
Trip Temperature
3.11
395191
SPST
293oF (145oC)
Element Assembly 240V 3.6 KW
Two sets of Nichrome wire elements linked in parallel
between Mica plates. A ceramic insulator is used to
support the element assembly in the housing.
Part Number
395274
Cold Resistance
13.5 Ohms
Current
15 Amps
Power
3.6 KW
Voltage
240 Volts (between two
phases)
3.12
Element Assembly 240V 1.4KW
Part Number
Cold Resistance
Current
Power
Voltage
3.13
395275
37 Ohms
5.8 Amps
1.4 KW
240 Volts (between two
phases)
Thermostat Cutout – Automatic Reset (Electrical)
Part Number
Type
Trip Temperature
Reset Temperature
395455
SPST
158oF ± 6o (70°C ± 3o)
131oF ± 7o (55°C ± 4o)
- 23 -
3.14
Thermostat Cutout – Manual Reset (Electrical)
Part Number
Type
Trip Temperature
3.15
Motor – 3 Phase 240W
Part Number
Voltage Rated
Power
Current
Speed
Resistance Across Any
Two Terminals of Plug
3.16
395155
SPST 30 Amps/240 Volts AC
212oF ± 11o (100oC ± 6o)
395378
190 Volts AC 85 Hz
240 Watts
1.6 Amps
2340 RPM
9.6 Ohms
Exhaust Temperature Sensor Loom
Part Number
395381
Resistance (+10%) at Various Ambients
32oF (0oC)
33 kOhms
50oF (10oC)
20 kOhms
o
o
68 F (20 C)
12 kOhms
86oF (30oC)
8 kOhms
5 kOhms
104oF (40oC)
3.17
Lid Lock
Part Number
Resistance range
420036P
63 Ohms +/- 10 Ohms
@ 68oF (20oC)
Safety extra low voltage.
- 24 -
3.18
Motor Control Module
Part Number
3.19
Sensor Module
Part Number
3.20
395400 (Electric models)
395401 (Gas models)
395394
Display Module
Part Number
395124
- 25 -
4
Diagnostics
4.1
Overview
If a fault occurs that prevents correct operation of the dryer, and is detected by the
controllers, the dryer is stopped, the display shows a fault code and the beeper is
continuously turned on and off. Pressing the Power button will stop the beeper but leave
the fault code displayed to help the service technician diagnose the problem. Pressing the
Power button again will remove the fault display and cause the dryer to try to start again.
If a fault occurs on a dryer, the user should be encouraged to turn the sound off (by
pressing the Power button once) but leave the displayed fault code on for easy
diagnostics.
The fault code is displayed in the LEDs of the Drying Progress display portion of the
display panel as shown below.
Each LED illuminated represents a binary code. By adding up the binary code value of the
LEDs that are illuminated, the fault code number can be determined.
In the example above the fault code is 8+2+1 = 11
Note: If the dryer has faulted and displayed a fault but the fault is currently not displayed,
most faults will manifest when the user attempts to run the dryer again. However, at any
time the “Last Fault” can be recalled from memory. Refer to Section 4.3.1 for method of
entry.
User Warnings
In the case of user warnings, the dryer may either pause, or “limp on”, and flash an LED
(see list below) at the same time as sounding a user warning. Pressing any button will
stop the sound, and pressing the Start or Power buttons, or the completion of the cycle,
will stop the display of the warning. The warnings are stored as “faults” in memory with
their warning or fault numbers, and can be recalled as “last fault” on the display, or by
downloading the information using the Fisher & Paykel Smart Tool diagnostic software.
- 26 -
4.2
Fault Code Summary
The following are the fault codes that may be displayed. The remedy section of each fault
is the suggested sequence of repair or replacement. If the first suggestion does not
remedy the fault, check the next on the list.
Fault Code 1
Communications Error.
Communications failure between the sensor module and motor control module.
Remedy: (1) Check the continuity of the module interconnecting harness.
(2) Replace the sensor module. (Refer to Section 6.36)
(3) Replace the motor control module. (Refer to Section 6.35)
Fault Code 2
Drum Gap Cannot be Located.
Remedy: (1)
(2)
(3)
(4)
Ensure the sensor module is correctly located and clipped into place.
Replace the lens on the sensor module.
Replace the sensor module. (Refer to Section 6.36)
Remove the top deck and clean the drum sensing “bumps” on the
outside of the drum end.
(5) Replace the drum. (Refer to Section 6.30)
Fault Code 3
Drum Stalled.
Remedy: (1) If there is mechanical movement of the drum, but this fault code is
appearing, follow the procedures for fault code 2.
(2) If there is no mechanical movement of the drum, check drum
movement mechanisms: belt, motor and motor harness.
(3) Replace the motor control module. (Refer to Section 6.35)
(4) Replace the motor. (Refer to Section 6.32)
- 27 -
Fault Code 4
Invalid Option Link Read.
The motor control module heat source option link read is invalid.
Remedy: Replace the motor control module. (Refer to Section 6.35)
Fault Code 6
Door Jammed - User Warning.
The door is unable to close due to either clothes catching or an excessive closing
load.
Remedy: (1) Remove the obstruction.
(2) Reposition or remove some of the load.
(3) Fix the cause of binding in the door closing mechanism.
(4) Replace the motor.
Fault Code 7
Motor Current Excessive.
Remedy: (1) Free up the dryer. Remove overload or cause of jamming.
(2) Replace the motor control module. (Refer to Section 6.35)
(3) Replace the motor. (Refer to Section 6.32)
- 28 -
Fault Code 8
Exhaust Sensor Over Temperature.
The exhaust sensor measures over temperature (fire detection, element short circuit
or low resistance).
Remedy: (1) Check the integrity of the sensor circuit checking particularly for short
circuits. Approximate resistances (+ 10%) at various temperatures
are; 32oF (0oC) = 33 KOhms, 72oF (22oC) = 11 KOhms, 104oF (40oC)
= 5 KOhms. Replace thermistor and harness if out of range.
(2) Check the element integrity in that it switches off when the dryer is
stopped.
(3) Replace the motor control module. (Refer to Section 6.35)
(4) Replace the sensor module. (Refer to Section 6.36)
Fault Code 9
Exhaust Sensor Under Temperature.
The exhaust sensor measures under temperature (open circuit or not plugged in).
Remedy: Refer to steps for over temperature fault (fault code 8) above, but open
circuit likely.
Fault Code 10
24 Volt Supply Measurement Error.
The sensor module measures low voltage on actuator power supply.
Remedy: Replace the sensor module. (Refer to Section 6.36)
Fault Code 11
Lid Lock Open Circuit.
Remedy: Check the lid lock harness and coil. If there is continuity through these,
replace the sensor module. (Refer to Section 6.36)
- 29 -
Fault Code 12
Lid Lock Switching Device Failure.
Remedy: Check that there are no short circuits in the lid lock circuit which may have
caused the failure in the sensor module. The resistance of the lid lock
should be between 50 and 100 ohms. If the circuit is correct, replace the
sensor module. (Refer to Section 6.36)
Fault Code 14
Sensor Module Fault.
Remedy: Replace the sensor module. (Refer to Section 6.36)
Fault Code 15
Sensor Module Fault.
Remedy: Replace the sensor module. (Refer to Section 6.36)
Fault Code 16
Airflow Restriction - User Warning.
Airflow restriction.
Remedy: (1) Check that the lint bucket is empty and the filter is clear.
(2) Ensure that the exhaust duct is not restricted, blocked or kinked,
preventing good airflow.
(3) Ensure that there is nothing inhibiting unrestricted airflow through the
heater housing, through the drum, lint filter, lint collector and through
the exhaust duct, and that the element has not shorted.
(4) Check that the voltage is not too high.
(5) Check for element shorts or low resistance, or that gas burner is
operating correctly.
(6) Replace the automatic thermostat. (Refer to Section 6.39)
(7) Replace the motor control module. (Refer to Section 6.35)
- 30 -
Fault Code 20
Door Actuator Stalled.
Remedy: As per fault code 21.
Fault Code 21
Door Actuator Required Excess Voltage.
Remedy: (1) Ensure there is no weight placed on the lid of the product (e.g. clothes
basket). If so, remove the weight and retest.
(2) Inspect the installation, making sure that the cabinet sits evenly on the
floor. If excess load is placed on the cabinet, it can cause the subdeck assembly to twist.
(3) Inspect the front inside edge of the top deck for any signs of excessive
inwards bowing as this can cause it to catch on the door grabber,
resulting in excess current draw on activation. The bowing can be
caused by a bowed top deck or by incorrect assembly of the top deck
to the cabinet front.
(4) Ensure the user intervention tab is not inhibiting door grabber
movement.
(5) Check that the actuator linkage is located correctly. There must be no
gap between the linkage and the plastic moulding (refer to Section 6.9
reassembly procedure).
(6) Check that the actuator housing is in place, and that the four retaining
lugs are correctly located (refer to Section 6.9). Early models may
have aluminium tape holding the housing in place. If so, ensure that
the tape is replaced when the housing is refitted.
(7) Remove the actuator housing and look for obvious signs of things that
are out of position (can the worm drive be rotated freely both
backwards and forwards by hand, is the actuator motor in place?)
(8) Replace the faulty door actuator mechanism. (Refer to Section 6.9).
(9) Replace the door grabber, linkage and housings. (Refer to Section
6.10)
(10) Replace the sensor module. (Refer to Section 6.36)
- 31 -
Fault Code 22
Door Actuator Open Circuit.
Remedy: (1) Check that the actuator wiring is plugged into the sensor module and
is not open circuit. If faulty, replace.
(2) Replace the sensor module. (Refer to Section 6.36)
Fault Code 23
Door Actuator Movement Interrupted By Low Voltage.
The door actuator movement was interrupted by low voltage (brown out).
Remedy: (1) Ensure mains voltage is within +10% and –15% of nominal.
(2) Replace the sensor module, as voltage measurement circuit may be
reading incorrectly. (Refer to Section 6.36)
(3) Replace the motor control module, as it may not be supplying
sufficient power to the sensor module.
When display is off,
approximately 24V DC is supplied. (Refer to Section 6.35)
Fault Code 24
Door Actuator Movement Took Too Long.
Remedy: As per fault code 21.
Fault Code 28
Data Retrieval Error Following Loss of Power
Remedy: (1) Switch off the mains power supply to the dryer for at least 10 seconds
and confirm error.
(2) Replace the motor control module. (Refer to Section 6.35)
- 32 -
Fault Code 29
Brown-Out Data Retrieval Error.
Remedy: (1) If the fault occurs every time the dryer is turned on, replace the sensor
module. (Refer to Section 6.36)
(2) Replace the motor control module. (Refer to Section 6.35)
Fault Code 30
Reason:
Lid Lock unable to Lock - User Warning.
The lid lock failed to lock. (Not user displayed.)
Remedy: (1)
(2)
(3)
(4)
Ensure the lid is closed and the tongue engaged.
Replace the lid lock harness. (Refer to Section 6.5)
Replace the lid lock. (Refer to Section 6.5)
Replace the sensor module. (Refer to Section 6.36)
Note: The blue Cool Down LED illuminated without the fault “beeps” indicates the dryer
is in a low mains voltage (brown out) state, and is momentarily displayed
whenever the supply power is turned off.
- 33 -
4.3
Diagnostic Mode
4.3.1
Entering the Diagnostic Mode
(a) Turn the power supply to the dryer on.
(b) Press and hold the Auto Dry down button, then press the Power button.
The dryer is now in level 0 of the diagnostic mode. After initial entry into the diagnostic
mode, the Start/Pause button operates the dryer as normal. Press the Auto Dry up or
down buttons to scroll through the fault levels.
There are several levels of diagnostics, most of which are used in development and
production. These levels may bring on various LEDs, but the level of use for the service
technician is that of the last fault.
4.3.1.1
Last Fault
To enter the last fault diagnostics, enter the diagnostic mode as described above, then
press the Auto Dry up button three times. The last fault will be displayed on the drying
progress LEDs as described in Section 4.1.
4.3.1.2
Conductivity Contact Impedance
To enter the conductivity contact impedance check, enter the diagnostic mode as
described above, then press the Auto Dry up button five times. In this mode, touching
damp clothes or fingers across the conductivity contacts will cause the LED display to
change. If the contacts, or the harness to them, have gone open circuit, no change will
occur in the LED display. This is a useful method of checking the integrity of the sensor
circuits.
To exit the diagnostic mode, press any cycle button.
4.3.2
Entering the Data Download Mode
(a) Turn the power supply to the dryer on.
(b) Press and hold the Auto Dry down button, then press the Power button. This enters
the diagnostic mode.
(c) Press the Regular button.
Encoded data is transmitted serially out the red Auto LED, and is captured by an optical
download pen attached to a PC where “Smart Tool” software interprets the data to aid
servicing.
To exit, press the Regular button.
4.3.3
Entering the Showroom Mode
(a) Turn the power supply to the dryer on.
(b) Press and hold the Air Dry button, then press the Power button.
The LEDs will flash in a random sequence.
To exit, turn off the power supply to the dryer at the wall.
- 34 -
5
Fault Diagnostics
5.1
Problem - No Power
The following checks are based on there being the correct supply voltage at the outlet and
the power cord is fastened securely to the dryer’s terminal block.
WARNING: The power must be turned off and the dryer disconnected from the
supply outlet to carry out the following checks.
5.1.1
(a)
(b)
(c)
5.1.2
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Check the Continuity of the Power Cord (Electric)
Remove the cover plate from the bottom right corner at the back of the machine
and check that the wiring connections are secure.
With an ohmmeter, check for continuity between
the neutral (N) terminal of the plug and the
centre connection on the terminal block in the
dryer, and between the appropriate pin on the
plug and the upper most terminal on the
terminal block of the dryer (L1 - red wire). Also
check between the appropriate pin on the plug
and the lower most terminal on the terminal
block (L2 - black wire). If there is continuity in
these wires, go to Section 5.1.2.
If there is no continuity, replace the power cord and retest the dryer.
Check the Continuity of the Main Harness (Electric)
Follow instructions for removal of components within the cabinet. (Refer to
Section 6.6)
Disconnect the main harness from the motor control module, manual resetable
thermostat and automatic reset thermostats.
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Pass the wiring loom out through exhaust duct.
Remove the cover plate from the bottom right
corner at the back of the machine.
Check the continuity from L1 on the terminal
block to the heater relay and the mains
connections on the motor control module (red
wires), and the continuity from L2 (black wires)
on the terminal block to the mains connector on the motor control module and
the manual resetable thermostat on the element carrier.
If there is no continuity, check that the terminal connections are secure. If so,
replace the mains harness.
If there is continuity in the harness, replace the motor control module and retest
the dryer.
- 35 -
5.1.3
(a)
(b)
(c)
(d)
(d)
5.1.4
(a)
(b)
(c)
(d)
(e)
5.2
Check the Continuity of the Power Cord (Gas)
Follow instructions for removal of the drum and chassis assembly. (Refer to
Section 6.16)
Pass the main power cord through the exhaust
duct.
Disconnect the 3 way in-line connector that is
clipped to the motor controller.
With an ohmmeter, check for continuity between
the neutral (N) terminal of the plug and the
outside connection on the in-line plug in the
dryer (white wire), and between the line/phase
pin on the plug and the centre connection on the
terminal block of the dryer (black wire).
If there is no continuity, replace the power cord and retest the dryer. If there is
continuity, go to Section 5.1.4.
Check the Continuity of the Main Harness (Gas)
Follow instructions for removal of the drum and chassis assembly. (Refer to
Section 6.16)
Disconnect the in-line connector that is clipped to the motor controller.
Check the continuity from the centre terminal on the in-line plug to the mains
connector on the motor control module (red wire), and from the outside terminal
on the in-line plug to the mains connector on the motor control module and the
gas valve (white wires).
If there is continuity, replace the motor control module and retest the dryer.
If there is no continuity, replace the mains harness and retest the dryer.
Problem - No Heat
5.2.1
Check All Thermostats (Gas and Electric)
WARNING: The power must be disconnected to perform the following checks.
(a) Check that the manual reset thermostat has not tripped. If it has, reset it.
(b) Disconnect each thermostat one by one and check the continuity of each.
(c) If any of the thermostats have no continuity, replace the offending thermostat. If
all thermostats have continuity, go to Section 5.2.2 (electric) or 5.2.5 (gas).
5.2.2
(a)
(b)
(c)
Check the Elements (Electric Only)
Follow instructions for removal of components within the cabinet. (Refer to
Section 6.6)
With an ohmmeter, measure the resistance across both elements.
(i) Measure the resistance of the 1.4kw element between the violet wire on the
front element connection and the violet wire on the mains relay on the motor
control module. The cold resistance should be between 38 and 45 ohms.
(ii) Measure the resistance of the 3.6kw element between the yellow wire on
the front element connection and the yellow wire on the relay on the motor
control module. The cold resistance should be between 13 and 19 ohms.
If there is an open circuit replace the element, otherwise go to Section 5.2.3.
- 36 -
5.2.3
Check Voltage Across Elements (Electric Only)
WARNING: Because the power must be on to carry out the following checks
extreme care must be taken as death or electrical shock can occur.
(a) Refit the top deck and reconnect the machine to power supply. Start the dryer
(Note: If there is no wet load in the dryer, the controller will turn the heat off
after a short space of time.)
(b) With the dryer running on a regular cycle in the closing direction, and with the
drum up to speed, use a voltmeter and measure the voltage of the 1.4kw
element, between the violet wire on the front element connection and the violet
wire on the mains relay on the motor control module. The voltage should be
equal to mains voltage of approximately 240V AC.
Measure the voltage of the 3.6kw element between the yellow wire on the front
element connection and the yellow wire on the relay on the motor control
module. The voltage should be equal to mains voltage of approximately 240V
AC.
(c) If there is no voltage, replace the motor control module and retest the dryer. If
there is voltage, go back to Section 5.2.1 and recheck.
5.2.4
Measure the Current Draw for Each Element (Electric Only)
This is an alternative to measuring the voltage.
(a) With a clamp amp meter, measure the current
draw of each element. Approximate current
draws are:
The Yellow lead = 5.8 amps.
The Orange lead = 15 amps.
Total current = 20.8 amps.
Note: The current draw will decrease as the elements
get hot.
5.2.5
5.2.5.1
(a)
(b)
(c)
5.2.5.2
(a)
(b)
Check the Gas Valve/Regulator (Gas Only)
Primary Coil
Disconnect the primary valve connector and
measure the resistance between terminals 1
and 2. Resistance should be 1.4 kOhms.
Measure the resistance between terminals 1
and 3. Resistance should be 560 ohms.
If the resistance is incorrect, replace the
valve/regulator. If the resistance is correct, go
to Section 5.2.5.2.
3 2 1
5 4
Connections
Secondary Coil
Disconnect the secondary valve connector and measure the resistance
between terminals 4 and 5. Resistance should be 1.3 kOhms.
If the resistance is incorrect, replace the valve/regulator. If the resistance is
correct, go to Section 5.2.6.
- 37 -
5.2.6
Check the Flame Detector (Gas Only)
The flame detector is much like a thermostat, although it is sensitive to radiant heat
whereas a thermostat relies more on conduction/convection to get hot. However
they are both essentially just switches. Therefore when it is cold the sensor should
be closed circuit (near zero resistance) and when the sensor is sufficiently hot the
switch will open (open circuit). Because it senses radiant heat, a temperature for
switching is not specified.
To test it, run the dryer and see if the flame detector goes open circuit after the igniter
has been on for a while (40-60 seconds depending on the voltage and air flow). It
should stay open circuit while the gas is burning and then cool down and close after
the gas flame goes out (about 30 seconds depending on the airflow and air temp).
5.2.7
Check the Igniter (Gas Only)
Disconnect the igniter and measure the resistance. Resistance should be
between 40 and 200 ohms when cold.
(a)
5.2.8
Check the Exhaust Sensor (Gas and Electric)
This check will need to be performed if the dryer has stopped functioning and fault
codes 8 or 9 have been displayed.
(a) Disconnect the temperature sensor from the sensor module and measure the
resistance. Resistance at various ambient temperatures should be (+/- 10%):
32ºF
50ºF
68ºF
86ºF
104ºF
(b)
(0ºC)
(10ºC)
(20ºC)
(30ºC)
(40ºC)
= 33 kOhm (+10%)
= 20 kOhm (+10%)
= 12 kOhm (+10%)
= 8 kOhm (+10%)
= 5 kOhm (+10%)
If the sensor resistance checks out correct, refer to Fault Codes in Section 4.2.
5.2.9
Check Inlet and Outlet Duct Seals
If the seals are faulty, replace. (Refer to Sections 6.26 and 6.20)
5.3
Problem – Drum Does Not Rotate
The following checks are based on the control panel LEDs lighting up when the Power
button is pressed, but no drum rotation when Start/Pause is pressed. Note: The lid must
be closed or else a warning sound will be given.
5.3.1
Check for Fault Code.
If a fault code is present, follow the instructions in Section 4.2.
5.3.2
(a)
(b)
Check the Integrity of the Belt.
Follow instructions for removal of components within cabinet. (Refer to Section
6.6)
Check that the belt is intact and in place. If not, follow instructions for removal
and replacement of the belt. (Refer to Section 6.29)
- 38 -
5.3.3
(a)
(b)
(c)
(d)
Check the Motor Windings.
Remove the cover of the motor control module. (Refer to Section6.35)
Unplug the motor harness from the motor control module.
Check the resistance of the motor windings at the plug end of the motor
harness. Resistance should be 9.6 ohms across any two terminals of the plug.
If the motor resistances are correct, replace the motor control module.
5.4
Problem - Under Drying/Damp
5.4.1
Possible User Faults
Ensure that the customer has chosen the correct cycle for the type of clothes
being dried.
Ensure that the customer has chosen the correct spin speed on the washing
machine. If the clothes are spun at a slow spin speed, they will be wetter and
will therefore take longer to dry.
(a)
(b)
5.4.2
(a)
(b)
5.4.3
(a)
(b)
(c)
Possible Installation Faults
Is the cabinet externally vented? If vented into the room, the damp air is being
recirculated through the dryer and will increase drying times.
Is the venting configuration within those specified in the installation instructions?
Excessive length or number of bends will restrict the airflow and decrease
drying performance.
Possible Maintenance Problems
Is all venting clear of lint, kinks, etc? Lint build up or kinks within the venting
system will restrict the airflow and decrease drying performance. Check the
inlet grill, burner inlet grill, venting and vent outlet grill/shutters to ensure that
they are clear.
Has the lint bucket been emptied?
Are the lint filter and exhaust sensor free of lint?
5.4.4
Check the Inlet and Outlet Duct Seals
A leak in either the inlet duct seal or the outlet duct seal can cause the hot air to
bypass the clothes load in the drum.
5.4.5
Check the Heating Circuits
Check the thermostats. (Refer to Section 5.2.1)
Electric models, check the elements. (Refer to Section 5.2.2).
Gas models, check the igniter, valve and flame detector. (Refer to Sections
5.2.5, 5.2.6 and 5.2.7.
(a)
(b)
(c)
5.4.6
Check the Moisture Sensing Circuit
(a) Check that the machine is correctly earthed.
(b) Check that the conductivity contacts are connected correctly.
(c) With the power disconnected from the dryer, use a suitable high impedance meter on
a high ohms range to measure the resistance between the conductivity contacts. It
should be 6.4 megohms (+1 megohm). Between either contact and the drum it
should be 4.3 megohms (+1 megohm).
(d) Check that the conductivity contacts circuit is registering the dryness levels of the
clothes. (Refer to Section 4.3.1.2)
- 39 -
5.5
5.5.1
(e)
(f)
Problem - Over Drying
Check the Moisture Sensing Circuit
(a) Check that the machine is correctly earthed.
(b) Check that the conductivity contacts are connected correctly.
With the power disconnected from the dryer, use a suitable high impedance meter on
a high ohms range to measure the resistance between the conductivity contacts. It
should be 6.4 megohms (+1 megohm). Between either contact and the drum it
should be 4.3 megohms (+1 megohm).
Check that the conductivity contacts circuit is registering the dryness levels of the
clothes. (Refer to Section 4.3.1.2)
- 40 -
6
Service Procedures
In order to service components of the SmartLoad™ dryer, certain procedures must be
followed. These procedures are set out below.
Servicing Note
(a) To avoid stripping screws, do not overtighten when re-assembling parts. If using a
power screw driver have the torque setting on low.
(b) Take extra care not to damage wire terminals on removal as some of these have
release clips.
(c) On completion of any service carried out to the dryer, all safety tests as required by
law must be carried out.
6.1
(a)
Removal of Lid
Open the lid fully, then lift off vertically.
Reassembly
(a) Refit in reverse manner, ensuring that the hinge lugs
on the lid are vertical.
Lift
6.2
(a)
(b)
(c)
(d)
Components in Console Area
Disconnect the unit from the power supply.
Remove the lid. (Refer to Section 6.1)
Remove the two screws at the rear of the console
securing the console to the top deck.
Tilt the console forward.
Reassembly
(a) Refit in reverse manner.
6.3
(a)
(b)
(c)
(d)
Screws
Removal of Display Module
Follow instructions for removal of the console.
(Refer to Section 6.2)
Disconnect the wiring harness from the display
module.
Push the tab clear and slide the module.
Lift the display module clear of the console.
Reassembly
(a) Refit in reverse manner.
Push tab
- 41 -
Slide module
6.4
Removal of Top Deck
6.4.1
If the top deck is to be removed for replacement:
(a) Follow instructions for removal of the console. (Refer
to Section 6.2)
(b) Disconnect the wiring harness from the display
module.
(c) Carefully remove the two lid buffers from the front
side top of the deck by levering upwards, taking care
not to damage the top deck.
(d) Remove two screws under the buffers securing the
top deck to the cabinet.
(e) Tilt the top deck upwards towards the rear.
(f) Disconnect the wiring harness from the sensor
module and lift the top deck clear.
(g) Remove the top deck harness from the top deck.
(h) Remove the lid lock, complete with harness, from the
top deck. (Refer to Section 6.5)
(i) Remove the stiffener brackets from under each side
of the top deck.
6.4.2
If the top deck is to be removed to gain access to other components:
(a) Follow instructions for removal of the lid. (Refer to
Section 6.1)
(b) Carefully remove the two lid buffers from front side top
of the deck by levering upwards, taking care not to
damage the top deck.
(c) Remove two screws under the buffers securing the top
deck to the cabinet.
(d) Tilt the top deck upwards towards the rear.
(e) Disconnect the wiring harness from the sensor module
and lift the top deck clear.
Reassembly
(a) Refit in reverse manner ensuring that the user
intervention lever is in its correct position and that the
cabinet top fits between the lugs on the inside front of
the top deck and the inside front edge of the top deck.
- 42 -
6.5
(a)
(b)
Removal of Lid Lock
Follow instructions for removal of the top deck. (Refer
to Section 6.4.2)
Remove the screw securing the lid lock to the
underside of the top deck, move the front downwards
and slide out.
Reassembly
(a) Refit in reverse manner.
6.6
(a)
(b)
(c)
Components Within Cabinet
Follow instructions for removal of the top deck. (Refer
to Section 6.4.2)
Remove the two screws securing the top of the front
panel.
Spread the top sides of the front panel to clear the
tabs on the door grabber assembly.
(d)
Pull the cabinet front forward and lift the base clear of
the feet.
(e)
Disconnect the cabinet front earth wire from the
chassis and lift the cabinet front clear.
Reassembly
(a) Refit in reverse manner.
6.7
(a)
(b)
(c)
(d)
(e)
Removal of Front Cabinet Brackets
Follow general servicing instructions for components within the cabinet. (Refer to
Section 6.6)
Invert the cabinet front.
Remove the screw securing the bracket to the cabinet
front.
Prise the retaining clip upwards.
Slide the bracket inwards then to the rear to clear the
cabinet front.
Reassembly
(a) Refit in reverse manner.
- 43 -
6.8
(a)
(b)
(c)
(d)
Removal of Door Grabber Assembly
Follow general servicing instructions for components within the cabinet. (Refer to
Section 6.6)
Close the drum door completely.
Disconnect the wiring from the door
grabber actuator at the sensor module.
Push the tabs in on the rear of the left and
right hand grabber housings and lift the
Push Tabs
assembly upwards and outwards.
Reassembly
(a) Refit in reverse manner.
6.9
(a)
(b)
(c)
(d)
Removal of Door Grabber Actuator
Follow instructions for removal of the door grabber assembly. (Refer to Section 6.8)
Unclip the wiring from the grabber housing.
While applying outward pressure to the actuator, push in the four retaining lugs (in
the order shown on the photo below) securing the actuator to the housing and lift the
actuator clear.
Slide the door grabber linkage out of the gear swivel.
2
3
1
Apply pressure
4
Push lugs
- 44 -
Linkage
Reassembly
(a) Refit in reverse manner.
(b) Ensure that the wiring to the actuator motor is clipped under the hooks and is in the
slots in the cover.
(c) With the actuator clipped into the grabber housing, ensure that the actuator linkage is
located correctly. There must be no gap between the linkage and the plastic
moulding of the housing.
Wiring in slot
Motor in place
Worm drive
can rotate
freely
Clipped under hooks
No gap between
linkage and
moulding at this
point
6.10
(a)
(b)
(c)
Removal of Door Grabber
Follow instructions for removal of the door grabber
actuator assembly. (Refer to Section 6.9)
Remove the four screws securing the chassis beam
to the grabber housings.
Lift the door grabber clear.
Reassembly
(a) Refit in reverse manner. Ensure that the linkage is
correctly located in the slot of the door grabber.
- 45 -
6.11
(a)
(b)
Removal of Door Bracket
Follow general servicing instructions for components within the cabinet. (Refer to
Section 6.6)
If the drum door is closed, push down on the tabs
on each side of the drum and slide the drum door
partially open.
(c)
Remove the centre clip by squeezing the tabs
together and pushing downwards.
(d)
Lift the loop of the hinge springs,
slide the springs out of the door
brackets and remove the clips.
Remove the hinge arms and locking
bar.
Slide the door bracket away from the
door. Slide one side forwards and
the other backwards to disengage it
from the tracks in the drum bridge.
(e)
(f)
Hinge Arm
Lift Spring
Door Bracket
Locking Bar
Reassembly
(a) Refit in reverse manner.
When refitting the hinge springs, ensure that they are not reversed or they will not sit
flat. Locate the longer (right hand) leg into the door bracket clips first, then the left
hand leg. Push home.
6.12
(a)
(b)
Removal of Drum Door
Follow instructions for removal of the door bracket. (Refer to Section 6.11)
Slide the door out of the tracks and lift clear.
Reassembly
(a) Refit in reverse manner.
- 46 -
6.13
(a)
(b)
(c)
(d)
Removal of Drum Door Buffers
Follow general servicing instructions for components within the cabinet. (Refer to
Section 6.6)
Remove the door grabber assembly. (Refer to
Section 6.8)
Slide the drum door open.
Unclip the drum door buffer and remove from
underneath the drum door by pushing on the tab.
Reassembly
(a) Refit in reverse manner.
Note: It is absolutely necessary that the drum door buffer is installed, as it provides static
discharge protection for the controllers.
6.14
(a)
(b)
(c)
(d)
Removal of Drum Door Key Bracket
Follow general servicing instructions for components
within the cabinet. (Refer to Section 6.6)
Slide the drum door partially open.
Push a small screwdriver blade through the holes in
the drum (4) to release the clips on the drum door key
bracket.
Lift the drum door key bracket clear.
Reassembly
(a) Refit in reverse manner.
6.15
(a)
(b)
Removal of Drum Door Scraper
Follow instructions for removal of the drum door.
(Refer to Section 6.12)
Lift up the drum door scraper to unclip it from the
drum.
Reassembly
(a) Refit in reverse manner.
- 47 -
6.16
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Removal of Drum and Chassis Assembly
Follow general servicing instructions for components within the cabinet. (Refer to
Section 6.6)
Follow instructions for removal of the door grabber assembly. (Refer to Section 6.8)
Remove the lid from the motor control module by pushing the clip on lid, lifting the
front of the lid and sliding forward.
Disconnect the earth wire from the outlet panel chassis to the base panel.
Disconnect the earth wire from the motor harness to the base panel.
Unplug the motor harness from the motor control
module.
Unplug the 6 wire communication harness from the
motor control module.
Lay a protective mat on the floor in front of the dryer.
Pull on the front of the panel chassis to pivot the
assembly out of the cabinet.
Roll the assembly clear of the cabinet.
Reassembly
(a) Refit in reverse manner.
6.17
(a)
(b)
(c)
(d)
(e)
Removal of Outlet Panel Assembly
Follow instructions for removal of the drum and chassis assembly. (Refer to Section
6.16)
Lay the assembly on its right hand side.
Remove the chassis panel bracket.
Remove the screws holding the chassis beams to the outlet panel, 2 from the front of
the outlet panel assembly (photo 1), 2 from the rear of the outlet panel assembly
(photo 2) and 2 from underneath the outlet panel assembly (photo 3).
Lift the outlet panel assembly clear.
Chassis panel bracket
Screws
Photo 1
Screws
Photo 2
Screws
Photo 3
Reassembly
(a) Refit in reverse manner. Ensure that the earth wire ring terminal is refastened to the
outlet panel assembly.
- 48 -
6.18
(a)
(b)
(c)
(d)
(e)
(f)
Removal of Outlet Duct Assembly
Follow instructions for removal of the outlet panel
assembly. (Refer to Section 6.17)
Remove the wiring loom plugs from the sensor
module assembly.
Remove the sensor module assembly from the outlet
chassis panel. (Refer to Section 6.36)
Lay the outlet panel assembly down with
the outlet chassis panel uppermost.
Remove the eight screws from the panel.
Lift the panel clear of the duct assembly.
Reassembly
(a) Refit in reverse manner.
6.19
(a)
(b)
(c)
Removal of Outlet Duct Bearings
Follow instructions for removal of the outlet panel
assembly. (Refer to Section 6.17)
Lift the collector housing bracket clear of the outlet
duct assembly.
With a screwdriver, push the tab on the back of the
bearing assembly to push it out of the outlet duct
assembly.
Reassembly
(a) Refit in reverse manner.
6.20
(a)
(b)
(c)
Bearing assembly
Removal of Outlet Duct Seal
Follow instructions for removal of the outlet duct
assembly. (Refer to Section 6.18)
Remove the outlet duct bearings. (Refer to Section
6.19
Grasp the seal and pull it out of the groove in the
outlet duct assembly, being careful not to tear the
seal away from the plastic strip that it is welded to.
Reassembly
(a) Refit in reverse manner.
- 49 -
6.21
(a)
(b)
(c)
Removal of Exhaust Sensor
Follow instructions for removal of the outlet duct
assembly. (Refer to Section 6.18)
Unclip the wiring loom and exhaust sensor harness
from the collector housing bracket.
Unclip the exhaust sensor from the pocket in the
collector housing bracket by pushing it forward, then
down.
Sensor Pocket
Harness
Clip
Reassembly
(a) Refit in reverse manner. Ensure that the exhaust sensor is correctly located in the
pocket in the collector housing bracket and that the exhaust sensor harness is pulled
tight and clipped into place.
6.22
(a)
(b)
Removal of Lint Collector Housing
Remove the lint bucket.
Remove the screw securing the lint collector housing
and lift the housing clear.
Reassembly
(a) Refit in reverse manner. Put the top in first and
ensure that the tab at the top of the housing slots in at
the top. Check that the top is secure when it is
assembled.
6.23
(a)
(b)
(c)
(d)
Removal of Conductivity Contacts
Follow instructions for removal of the lint collector
housing. (Refer to Section 6.22)
Push the tabs on the conductivity contact bracket to
release the bracket from the collector housing.
Remove the harness wires from the conductivity
contacts.
Unclip the contacts from the bracket.
Reassembly
(a) Refit in reverse manner, ensuring that one harness wire is connected to each
conductivity contact, and that the contacts are not touching each other.
- 50 -
6.24
(a)
(b)
Removal of Belt Tensioner
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Remove the belt tensioner assembly by pushing
against the spring tension and unclipping from
the rear chassis beam.
Push Belt Tensioner
A screwdriver can be used to unclip it by
putting the blade through the slot and levering
against the beam.
(c)
Lift the top of the belt tensioner assembly clear and
unclip it from the centre chassis beam. Lift clear.
Reassembly
(a) Refit in reverse manner.
- 51 -
6.25
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Removal of Inlet Panel Assembly
Follow instructions for removal of the drum and chassis assembly. (Refer to Section
6.16)
Manually open the drum door.
Remove the drum inlet bearing. (Refer to Section 6.28)
Lay the assembly on its left hand side.
Remove the belt tensioner. (Refer to Section 6.24)
Remove the chassis panel bracket.
Remove the screws holding the chassis beams to the inlet panel, 2 from the front of
the inlet panel assembly (photo 1), 2 from the rear of the inlet panel assembly (photo
2) and 2 from underneath the inlet panel assembly (photo 3).
Chassis panel bracket
Screws
Photo 1
(h)
Screws
Photo 2
Screws
Photo 3
Lift the inlet panel assembly clear.
Reassembly
(a) Refit in reverse manner. Do not overtighten the screw securing the drum inlet cap.
Tighten to 7 newton metres (1.5 foot pounds).
6.26
(a)
(b)
Removal of Inlet Duct Seal
Follow instructions for removal of the inlet panel
assembly. (Refer to Section 6.25)
Unclip the lugs on the inlet duct seal from the front
inlet duct and lift the seal clear.
Reassembly
(a) Refit in reverse manner.
Lugs
- 52 -
6.27
(a)
(b)
Removal of Inlet Bearing Shaft
Follow instructions for removal of the inlet panel
assembly. (Refer to Section 6.25)
With a deep bore 22mm (7/8”) socket, unscrew the
inlet bearing shaft and remove.
Reassembly
(a) Refit in reverse manner. Before refitting the inlet
bearing shaft, ensure that the inlet bearing spacer is
in position on the bolt between the inlet duct front
panel and the inlet duct back panel. Tighten to a torque of 20 newton metres (15 foot
pounds).
6.28
(a)
(b)
(c)
(d)
Removal of Drum Inlet Bearing
Lift the lid./
Remove the drum inlet bearing cap by
unscrewing with a M5 or 3/16” Allen key.
Remove the 5 screws securing the bearing
retainer to the drum and remove the retainer.
While lifting the drum slightly, slide the bearing and
housing off the shaft.
Reassembly
(a) Refit in reverse manner. Ensure that the bearing housing is orientated so that the
rivet heads sit in the clearance holes. Lift the drum upwards while sliding the bearing
onto the shaft. Do not overtighten the screw securing the drum inlet cap. Tighten to
10 newton metres (7 foot pounds).
- 53 -
6.29
(a)
(b)
(c)
(d)
Removal of Belt
Follow instructions for removal of the belt tensioner. (Refer to Section 6.24)
Remove the outlet panel assembly. (Refer to Section 6.17)
Remove the belt from the motor pulley.
Remove the belt from around the drum.
Reassembly
(a) Refit in reverse manner.
6.30
(a)
(b)
Removal of Drum
Follow instructions for removal of the belt. (Refer to Section 6.29)
Lift the drum clear.
Reassembly
(a) Refit in reverse manner.
6.31
(a)
(b)
(c)
Removal of Lint Filter Assembly
Remove the screw on the inside bottom of the drum securing
the lint filter retainer to the drum.
Turn the lint filter retainer clockwise to unclip it from the drum,
then pull clear of the drum.
Unclip the lint filter assembly from the lint filter retainer.
Reassembly
(a) Refit in reverse manner, ensuring that when fitting the lint
filter retainer to the drum, the screw hole in the retainer lines
up with the screw hole in the drum.
6.32
(a)
(b)
(c)
(d)
(e)
Removal of Motor
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Remove the belt tensioner. (Refer to Section 6.24)
Remove the screw securing each of two motor
mounting clamps. Lift the clamps clear.
Lift the fan housing clear.
Lift the motor and fan clear of the fan motor housing.
Reassembly
(a) Refit in reverse manner. Ensure that the motor is
rotated so that the harness lines up with the harness retaining clip on the fan housing
and that the harness is cable tied to the beam.
- 54 -
6.33
(a)
(b)
(c)
Removal of Fan
Follow instructions for removal of the motor. (Refer to
Section 6.32)
Remove the circlip securing the fan to the motor shaft.
While sitting in a chair, place feet on top of the base of
the fan and pull upwards on the motor. This will pull
the motor shaft out of the spline in the fan.
Reassembly
(a) Refit in reverse manner, lining up the spline on the
motor shaft with the spline in the fan and pushing the
motor shaft into the fan boss sufficiently to refit the fan
retaining circlip. Do not hit the motor shaft.
(b) Refit the circlip to the motor shaft.
6.34
(a)
(b)
Removal of Fan Motor Housing
Follow instructions for removal of the motor. (Refer to
Section 6.32)
Use fingers to unclip the three clips from the centre beam.
Spring the housing off over the centre beam, tilt horizontally
and unhook from the rear beam.
Reassembly
(a) With the housing horizontal, hook it over the rear beam and
tilt it down to rest on the centre beam.
(b) Slide the housing on the beam to allow the spring clip to
engage the slot in the rear beam.
(c)
(d)
Spring clip in slot
Press on the housing to spring it over the centre beam (check
that the locating spike is engaged in the locating slot in the
centre beam).
Press on the housing at three lug locations to snap the three
clips over the centre beam.
Spike
Locating slot
- 55 -
6.35
(a)
(b)
(c)
(d)
(e)
Removal of Motor Control
Module
Follow general servicing instructions for components
within the cabinet. (Refer to Section 6.6)
Remove the screw securing the front of the module
to the base panel.
Push in the tab below this screw and lift the front of
the module upwards.
Unplug the wiring connectors from the module.
Slide the module forward to disengage the tab at the rear from the base panel.
Reassembly
(a) Refit in reverse manner.
6.36
(a)
(b)
(c)
Removal of Sensor Module
Follow instructions for removal of the top deck.
(Refer to Section 6.4.2)
Unplug the wiring connectors from the module.
Push in the tabs on the sides of the sensor module
and slide it upwards.
Tabs
Reassembly
(a) Refit in reverse manner.
6.37
(a)
(b)
(c)
(d)
(e)
Removal of Gas Igniter (Gas
Models)
Follow general servicing instructions for components
within the cabinet. (Refer to Section 6.6)
Using a small screwdriver, prise the connector apart.
Remove the screw securing the igniter bracket to the
gas burner bracket and lift the igniter bracket tabs
clear of the slots in the burner bracket.
Carefully extract the igniter from the chamber.
Bend the tabs on the igniter bracket clear and
remove the igniter.
Reassembly
(a) Refit in reverse manner. Ensure that the igniter is positioned about ¼” (6mm) away
from the burner.
6.38
(f)
(g)
(h)
Removal of Flame Detector (Gas Models)
Follow general servicing instructions for components
within the cabinet. (Refer to Section 6.6)
Remove the push on connectors from the flame
detector terminals.
Remove the screw securing the flame detector to
the bottom combustion housing and lift clear.
Reassembly
(a) Refit in reverse manner.
Flame detector
- 56 -
6.39
(a)
(b)
(c)
Removal of Thermostats
Follow
general
servicing
instructions
for
components within the cabinet. (Refer to Section
6.6)
Remove the push on connectors from the
appropriate thermostat terminal.
Remove the screw securing the thermostat to the
combustion housing and lift the thermostat clear.
Reassembly
(a) Refit in reverse manner.
6.40
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Thermostats
Removal of Gas Regulator Valve, Pipe and
Burner Tube (Gas Models)
Disconnect the dryer from the gas supply.
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Remove the push on connectors from the
thermostat attached to the top combustion housing.
Remove the screw securing the top combustion
housing to the bottom combustion housing, hinge
up and lift clear.
Remove the push on connectors from the gas
Gas regulator valve
regulator valve.
Remove the screw securing the gas igniter bracket and lift the bracket clear.
Slide the gas burner bracket to the left and lift clear of the slots in the base panel. Lift
the gas regulator valve and pipe assembly forward and out.
Remove the two screws securing the gas burner venturi.
Remove the three screws securing the gas regulator valve to the bracket.
Unscrew the gas pipe from the gas regulator valve.
Reassembly
(a) Refit in reverse manner. Ensure that the regulator/valve is screwed onto the gas
pipe to the correct angle so that the gas burner bracket sits flat on the base panel
when assembled. Ensure that the gas pipe bracket tabs go through the slots in the
back of the base panel.
6.41
(a)
(b)
(c)
(d)
(e)
(f)
Removal of Elements (Electric Models)
Follow instructions for removal of the drum and chassis assembly. (Refer to Section
6.16)
Remove the push on connectors from the thermostat attached to the top combustion
housing.
Remove the screw securing the top element housing
to the bottom element housing.
Lift the top housing clear.
Remove the push on connectors from the
element.
Lift the element clear.
Reassembly
(a) Refit in reverse manner.
- 57 -
6.42
(a)
(b)
(c)
(d)
(e)
Removal of Front Foot Bracket Assembly
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Lay the cabinet on its side on a protective surface,
with the foot bracket to be removed uppermost.
With a screwdriver, push inwards on the rear tab of
the foot bracket.
When this tab is clear of the base panel, slide it
towards the rear about ¾” (18mm).
The foot bracket assembly can now be hinged
outwards and removed from the cabinet.
Reassembly
(a) Refit in reverse manner.
6.43
(a)
(b)
(c)
(d)
(e)
(f)
Removal of Rear Foot Bracket Assembly
Follow instructions for removal of the drum and
chassis assembly. (Refer to Section 6.16)
Remove the rear intake grill by levering the four
tabs downwards with the fingers. Pull the top of the
intake grill outwards and disengage the bottom lugs
from the base panel. Lift clear.
Lay the cabinet on its side on a protective surface,
with the foot bracket to be removed uppermost.
With a screwdriver, push inwards on the front tab of
the foot bracket.
When this tab is clear of the base panel, slide it
towards the front about ½” (12mm).
The foot bracket assembly can now be hinged
outwards and removed from the cabinet.
- 58 -
(g)
Push the tab on the foot adjusting guide.
(h)
Push the rear of the guide through the base panel
and lift clear.
(i)
(j)
Push the foot upwards to clear the top of the foot
adjusting guide.
Slide the foot sideways to remove it from the strap.
(k)
Draw the strap back through the housing.
Push upwards on the strap to disengage it from the hooks
on the guide. Pull the strap clear.
Reassembly
(a) Refit in reverse manner.
- 59 -
7
Wiring Diagrams
7.1
U.S.A. Model (Electric)
- 60 -
7.2
U.S.A. Model (Gas)
- 61 -
8
Fault Finding Flow Charts
8.1
No Power
Is there
power to the
supply
outlet?
No
Arrange repair of
supply etc. as
necessary
Yes
Is the power
cord fitted
correctly?
No
Refit correctly
Yes
Is there
continuity of
the power
cord?
Check as per
Section 5.1.1
(Electric) or 5.1.3
(Gas)
Yes
Is there
continuity of
the main
harness?
Check as per
Section 5.1.2
(Electric) or 5.1.4
(Gas)
Yes
Fit new motor
control
module
- 62 -
8.2
No Heat (Electric Models)
Is a fault
code
displayed?
Yes
Refer to Section
4.2
No
Are
thermostats
OK?
Check as per
Section 5.2.1
Repair/replace as
necessary
Yes
Are element
resistances
OK?
Replace motor
control module
Check as per
Section 5.2.2
Repair/replace as
necessary
Yes
Yes
Fit new inlet duct
seal. Refer Section
6.26
No
Are the
elements
drawing the
correct
current?
Is the inlet
duct seal
OK?
Yes
Yes
Fit new outlet duct
seal. Refer Section
6.20
No
Is the outlet
duct seal
OK?
Check as per
Sections 5.2.3 and
5.2.4
Yes
- 63 -
Are exhaust
sensor
resistances
OK?
Check as per
Sections 5.2.8 and
repair/replace as
necessary
8.3
No Heat (Gas Models)
Is a fault
code
displayed?
Replace sensor
module
Yes
Refer to Section
4.2
No
Reinstate supply
Yes
Reset thermostat.
Replace if
necessary
Yes
No
Fit new inlet duct
seal. Refer Section
6.26
No
Is the inlet
duct seal
OK?
Is the gas
supply OK?
Yes
Yes
Fit new outlet duct
seal. Refer Section
6.20
No
Has the
overheat
thermostat
tripped?
Is the outlet
duct seal
OK?
No
Yes
Check as per
Sections 5.2.8 and
repair/replace as
necessary
Are exhaust
sensor
resistances
OK?
Are gas valve
resistances
OK?
Yes
Yes
Check as per
Section 5.2.6
Is the flame
detector
operating
correctly?
Check as per
Section 5.2.5
Repair/replace as
necessary
Yes
- 64 -
Are gas
igniter
resistances
OK?
Check as per
Section 5.2.7
Repair/replace as
necessary
8.4
Drum Door Not Opening/Closing
Is a fault
code
displayed?
Yes
Refer to Section
4.2
No
Rectify fault
No
Rectify fault
No
Repair as
necessary
No
Are jockey
pulleys free &
belt aligned
OK?
Yes
Check manual
operation of
drum door for
jamming etc.
OK?
Yes
Is actuator
operating
OK?
Yes
Replace bearing.
Refer Section 6.28
Yes
Is drum inlet
bearing tight?
No
- 65 -
Is cabinet
racked?
Yes
Level cabinet
8.5
Drum Does Not Rotate
Is a fault
code
displayed?
Yes
Refer to Section
4.2
No
Are the
jockey
pulleys free &
belt aligned
OK?
Refit/repair as
necessary
Yes
Are motor
winding
resistances
correct?
No
Refer to Section
5.3.3
No
Repair/replace
Yes
Is continuity
of harness to
motor OK?
Yes
Replace motor
control module
- 66 -
8.6
Clothes Take Too Long to Dry
Clean
No
Are the inlet
grill & burner
inlet grill free
of lint?
Is a fault
code
displayed?
No
Are the
conductivity
contacts clean and
connected
correctly?
Has the
correct cycle
been chosen
for the type of
clothes?
No
Are the lint
filter &
exhaust
sensor free of
lint?
Is cabinet
vented
externally?
No
Has correct
spin speed
been used in
washing
machine?
Is heater
operating?
No
No
Advise customer
on correct venting
methods
No
Advise customer to
use correct spin
speeds to aid
drying
No
Clear restrictions.
Advise customer
on correct venting
methods.
Yes
Yes
Fit new seals.
Refer Sections
6.20 and 6.26
Advise customer to
use correct cycle
Yes
Yes
Refer Section 8.2
(electric) or Section
8.3 (gas)
No
Yes
Yes
Clean & check
sensor as per
Section 5.2.8
Refer to Section
4.2
No
Yes
Clean and/or
reconnect correctly.
Check as per
Section 5.4.5
Yes
Are inlet &
outlet duct
seals OK?
Yes
Is the venting
clear, not too
long, not too
many bends
etc?
Refer to installation
instructions
- 67 -
8.7
Noisy
Repair
Yes
Are jockey
pulleys free &
belt aligned
OK?
Is ducting
damaged?
No
Are drum
vanes tight?
Are motor or
fan loose?
No
Is there
excessive lint
build up on
the fan
blades?
Is the inlet
duct seal
OK?
No
Are outlet
duct bearings
OK?
Is outlet duct
seal OK?
No
Is the drum
inlet bearing
free?
Yes
Clean
No
Fit new outlet duct
seal. Refer Section
6.20
Yes
Yes
Fit new bearing
Refer Section 6.28
Rectify fault
No
Yes
Fit new bearings.
Refer Section 6.19
Yes
No
Yes
Fit new inlet duct
seal. Refer Section
6.26
Rectify fault
Yes
Yes
Tighten vanes
No
Yes
- 68 -
Check manual
operation of
drum door for
distortion etc.
O.K?
No
Rectify fault
Notes
- 69 -